A team of researchers has developed a new double-layered battery coating that provides quick response and long-lasting protection against fire. This coating is only 320 microns thick, even thinner than a credit card, but provides thermal insulation and fire safety far superior to standard and existing battery coverings. 

Published in Nano-Micro Letters, the study shows that despite its thickness, the bi-layered coating can withstand fire temperatures of up to 1400℃ for more than 900 seconds. The coating achieves this through the quick defense provided by the outer layer and the long-term shield from the inner layer.

On the exterior surface of the coating is an intumescent flame-retardant (IFR) layer, which contains alumina synergists. When the IFR gets heated below 300℃, it quickly expands and forms a char barrier. This response delivers fast and reliable protection, even before the heat intensifies. 

On the inner side of the coating is a ceramifiable layer, which has fillers such as low-melting glass powder. This material changes when exposed to around 550℃. Instead of forming a char barrier, it develops into a tough, ceramic barrier that remains solid.

Researchers have designed this bi-layer coating to provide even more protection at higher temperatures. At 800℃, the IFR layer maintained 31% of its mass, while the ceramifiable layer retained over 97% residue.

The tests conducted by the team have exhibited the bi-layer coating's capability to efficiently and effectively deliver immediate and long-lasting protection, even in commercial use across different industries and sectors. 

Moreover, the study has shown that this coating works well with various substrates, such as aluminum, polyurethane foam, and glass fabric-reinforced epoxy resin. Even better, it positions this coating as a template for even better-performing flame-retardant coatings. 

Read the full article here to learn more about the bi-layered coating.

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